EP0695596B1 - Rotary cutting tool and method of manufacturing the same - Google Patents

Rotary cutting tool and method of manufacturing the same Download PDF

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Publication number
EP0695596B1
EP0695596B1 EP95110087A EP95110087A EP0695596B1 EP 0695596 B1 EP0695596 B1 EP 0695596B1 EP 95110087 A EP95110087 A EP 95110087A EP 95110087 A EP95110087 A EP 95110087A EP 0695596 B1 EP0695596 B1 EP 0695596B1
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EP
European Patent Office
Prior art keywords
inserts
helical
sintered compact
insert
ultra
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95110087A
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German (de)
English (en)
French (fr)
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EP0695596A1 (en
Inventor
Makoto C/O Itami Works Of Sumitomo Abe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
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Publication date
Application filed by Sumitomo Electric Industries Ltd filed Critical Sumitomo Electric Industries Ltd
Publication of EP0695596A1 publication Critical patent/EP0695596A1/en
Application granted granted Critical
Publication of EP0695596B1 publication Critical patent/EP0695596B1/en
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/16—Milling-cutters characterised by physical features other than shape
    • B23C5/18—Milling-cutters characterised by physical features other than shape with permanently-fixed cutter-bits or teeth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/02—Milling-cutters characterised by the shape of the cutter
    • B23C5/10—Shank-type cutters, i.e. with an integral shaft
    • B23C5/1081—Shank-type cutters, i.e. with an integral shaft with permanently fixed cutting inserts 
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2210/00—Details of milling cutters
    • B23C2210/20—Number of cutting edges
    • B23C2210/203—Number of cutting edges four
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
    • B23C2222/76—Silver
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2224/00—Materials of tools or workpieces composed of a compound including a metal
    • B23C2224/28—Titanium carbide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2224/00—Materials of tools or workpieces composed of a compound including a metal
    • B23C2224/32—Titanium carbide nitride (TiCN)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2224/00—Materials of tools or workpieces composed of a compound including a metal
    • B23C2224/36—Titanium nitride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2226/00—Materials of tools or workpieces not comprising a metal
    • B23C2226/12—Boron nitride
    • B23C2226/125—Boron nitride cubic [CBN]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2226/00—Materials of tools or workpieces not comprising a metal
    • B23C2226/31—Diamond
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool
    • Y10T407/1946—Face or end mill
    • Y10T407/1948—Face or end mill with cutting edge entirely across end of tool [e.g., router bit, end mill, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/19—Rotary cutting tool
    • Y10T407/1952—Having peripherally spaced teeth
    • Y10T407/1962—Specified tooth shape or spacing
    • Y10T407/1964—Arcuate cutting edge
    • Y10T407/1966—Helical tooth
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/26—Cutters, for shaping comprising cutting edge bonded to tool shank
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T407/00—Cutters, for shaping
    • Y10T407/27—Cutters, for shaping comprising tool of specific chemical composition

Definitions

  • the present invention relates to a rotary cutting tool according to the precharacterising portion of claim 1 and 2 respectively having helical edges comprising helical inserts made from an ultra-high-pressure sintered compact, such as a spiral end mill, a spiral reamer or a drill, an insert made from an ultra-high-pressure sintered compact for use in the aforementioned tool, and a method of manufacturing such a tool and an insert at low cost.
  • an ultra-high-pressure sintered compact such as a spiral end mill, a spiral reamer or a drill
  • an insert made from an ultra-high-pressure sintered compact for use in the aforementioned tool
  • a rotary cutting tool having helical edges having a large helix angle has an excellent cutting performance and can machine a workpiece with high precision because its teeth bite into the workpiece continuously, i.e. rear portions of the teeth can bite into the workpiece before their leading portions separate from the workpiece.
  • such cutting tools may be manufactured by forming a blade of tungsten carbide or high speed steel and brazing, bonding or clamping the blades to seats of a tool body.
  • a milling tool by brazing a milling head to a tool body in a plane vertical to the axis of the milling tool.
  • the milling head consists of ceramic comprising a matrix, e.g. an aluminum or silicon matrix, and a reinforcing material such as silicon carbide whiskers.
  • the milling head and the tool body are brazed using a brazing metal comprising 63% Ag, 35.25% Cu and 1.75% Ti by weight.
  • FR-A-1 193 210 discloses a tool comprising a tool body made of steel in which inserts made of tungsten carbide or high speed steel are mounted. The inserts are brazed to the tool body, wherein a layer of more than 0.5mm of sintered metal may be applied to the inserts in order to provide a more elastic joint as compared to directly brazing the insert to the tool body.
  • an ultra-high-pressure sintered compact formed by sintering a powder of diamond, high-pressure phase type boron nitride, or their mixture under ultra-high pressure has excellent wear resistance. But in order to form helical flutes from such ultra-high-pressure sintered compact, there remain many problems that have to be solved.
  • an ultra-high-pressure sintered compact is usually formed as a flat plate as shown in Fig. 3.
  • the plate material 15 shown in Fig. 3 has a double-layer structure comprising a cemented carbide base 17 and an ultra-high-pressure sintered compact 16.
  • the thickness of the compact 16 is usually limited not to exceed 1 mm. Because of this restriction of thickness, it is impossible to cut a helical insert having a helix angle of more than 5° out of this plate material 15. The cutting performance is low with such a helical insert because of its small helix angle.
  • Unexamined Japanese Patent Publication 3-277412 proposes one solution to this problem. It proposes to form helical grooves in a sintered compact substrate, fill the grooves with a material powder, and sinter the material powder under ultra-high pressure to anchor it to the sintered compact substrate.
  • the applicant of the present invention proposed in Unexamined Japanese Publication 3-10707 to form a columnar or cylindrical member by integrally forming a peripheral layer of a ultra-high-pressure sintered compact around a base metal as a core, and form helical surfaces that intersect the outer cylindrical surface of the member on both sides thereof by cutting it longitudinally.
  • the technique disclosed in Unexamined Japanese Patent Publication 3-277412 has an advantage in that it is necessary to bond the insert to the tool body after sintering the insert because the sintered compact base itself is used as the tool body. Also, since the helix angle of the grooves can be determined freely, the lead angle of the cutting edge can be also freely determined But this technique has several problems. One problem is that the manufacturing efficiency of inserts is low. Another problem is that a large part of the sintered compact base has to be removed when finishing it to the shape of a tool. This inevitably pushes up the machining cost. Also, this technique requires a rather long time for machining and thus the productivity is low.
  • a material including a base metal tends to develop cracks in its ultra-high-pressure sintered compact due to the difference in thermal expansion coefficient between the base metal and the sintered compact. Cracks may also develop in the sintered compact when cutting a helical insert from the material including a base metal by electrical discharge machining. Thus, this technique is still unsatisfactory in the yield of materials as well as the yield of inserts cut from the material.
  • the material for inserts includes no base metal. If we find a way to bond an insert of an ultra-high-pressure sintered compact as disclosed in Unexamined Japanese Patent Publication 3-10707 but including no base metal directly to a tool body, it will be possible to greatly reduce the tool manufacturing cost. Without base metals, it will be also possible to reduce the defective rate when forming materials for inserts and when cutting inserts from such insert material. This leads to further reduction in the manufacturing cost.
  • a first object of the present invention is to provide a method of bonding an insert of an ultra-high-pressure sintered compact including no base metal to a tool body, and to provide a rotary cutting tool having helical inserts formed by this method and which is high in cutting ability, cutting accuracy and durability and less expensive.
  • the columnar sintered compact used in Unexamined Japanese Patent Publication 3-10707 has a double-layer structure comprising a base metal 13 of a cemented carbide, and a hard sintered compact 14 integrally formed around the base metal 13.
  • a base metal 13 of a cemented carbide a cemented carbide
  • a hard sintered compact 14 integrally formed around the base metal 13.
  • the upper limit of the ratio of the thickness t of the sintered body to its diameter d i.e. the ratio t/d is about 1/2 to 1/3.
  • Another problem of the method disclosed in Unexamined Patent Publication 3-10107 is that since a helical insert is formed by cutting longitudinally the sintered compact (material for inserts) having a height t, the effective length of the cutting edge of the insert is limited by the height t. Namely, it is impossible to form an insert having a long cutting edge.
  • a second object of the present invention is to provide a rotary cutting tool having helical inserts of ultra-high-pressure sintered compact which are free of the aobvementioned problems, and a method of manufacturing such inserts.
  • a rotary cutting tool having the features of claim 1 and 2 respectively and a method of manufacturing the same.
  • inserts are secured to a tool body by forming a film coating of a Ti compound on the surface of the inserts, and then silver-brazing the inserts to the tool body in the atmosphere.
  • the rotary cutting tool thus formed has a bonding layer of Ti-containing activated silver brazing filler metal or a Ti compound film and a silver brazing filler metal disposed between the ultra-high-pressure sintered compact insert including no base metal and the tool body.
  • the helical insert of an ultra-high-pressure sintered compact according to the present invention has helical side faces formed by cutting a columnar or cylindrical member longitudinally along two helical planes. It is formed solely from an ultra-high-pressure sintered compact and includes no base metal.
  • the method of manufacturing helical inserts of an ultra-high-pressure sintered compact comprises the steps of forming a plurality of cylindrical or columnar members by cutting a single block of an ultra-high-pressure sintered compact, and cutting each member longitudinally along helical planes to form inserts having helical side faces.
  • brazing inserts of ultra-high-pressure sintered compact to a tool body under vacuum using Ti-containing activated silver as a brazing metal, they can be bonded strongly to the tool body.
  • the inserts By forming a coating of a Ti compound such as TiC, TiN or TiCN on the surface of inserts, the inserts can be bonded strongly to the tool body by brazing even in the atmosphere.
  • a Ti compound such as TiC, TiN or TiCN
  • the inserts are bonded so rigidly to the tool body that it is possible to prevent the inserts from dropping off when machining them to adjust their rake angle or clearance angle or while the tool is being used for actual cutting.
  • the tool can be used safely.
  • the insert according to the present invention is formed solely from an ultra-high-pressure sintered compact and includes no base of cemented carbide, no stress resulting from a difference in thermal expansion coefficients will be produced in the insert, so that it is less likely to be broken or develop cracks. But it is usually very difficult to bond such an insert to a tool body by ordinary brazing. But we have found two ways to do this.
  • Ti-containing activated silver is used as a brazing metal.
  • a metal having a composition of 60-80 wt % of Ag, 10-20 wt % of Cu and 0.5-10 wt % of Ti were the most desirable.
  • Ti is the most important element. If the brazing metal contains no Ti or the Ti content is less than 0.5 wt %, the bond strength between the insert and the tool body will be insufficient.
  • a brazing metal containing more than 10 wt % Ti is so high in melting point that it is difficult to use.
  • the Ti content is within the range between 2 and 5 wt %. Within this range, helical inserts of ultra-high-pressure sintered compact can be bonded stably and strongly to the tool body.
  • the brazing temperature should be lower than about 900°C.
  • the lower limit of the brazing temperature is determined by the melting point of the brazing metal used. The melting point can be lowered by adding low-melting point elements such as In and Sn to the brazing metal. But the lowest possible melting point would be about 700°C at most. Brazing metals will not melt at temperatures below 700°C.
  • Ti-containing activated silver is used for brazing in the atmosphere, the effect of addition of Ti will not expected. Namely, the content of Ti, which contributes to increase the bond strength between the tool body and an ultra-high-pressure sintered compact, will decrease because Ti reacts with oxygen and nitrogen in the air to such an extent that the bond strength decreases below the necessary level.
  • brazing using Ti-containing activated silver as brazing metal should be carried out under vacuum.
  • the degree of vacuum should be set slightly higher than that ordinarily employed in ordinary vacuum brazing (about 10 -1 Torr), more specifically about 10 -3 Torr.
  • the tool according to the present invention has a larger joint area and thus higher bond strength between the insert and the tool body than the conventional tool.
  • a block made solely of an ultra-high-pressure sintered compact and including no base metal is the least likely to develop cracks when forming an insert or subjecting the block to electrical discharge machining.
  • cylindrical or columnar insert materials are cut from such a block, it is possible to form a plurality of insert materials of the same or different kind and diameter from a single block.
  • Forming a single block requires substantially the same trouble as forming a single insert material by direct sintering.
  • three insert materials are formed from a single block, they can be formed about three times more efficiently.
  • a plurality of helical inserts can be formed from each insert material. This further reduces the manufacturing cost per insert. The smaller the diameter of the inserts to be formed, the greater the number of inserts obtained from a single block. Thus, the advantage of the present invention will be felt more remarkably when forming small-diameter tools.
  • insert materials are cut from a block in one of the three ways shown in Figs. 8-10 (which we will discuss in more detail later). In any of these ways, a plurality of insert materials are obtainable from a single block.
  • the Lmax will be only 16 mm because it is restricted by the value t in Fig. 14.
  • the smaller the diameter d of the insert material the larger the value L can be made.
  • it is impossible to reduce only the diameter d Namely, if the diameter d is small, the value t has to be correspondingly small. Thus, it is difficult to form a tool having sufficiently long cutting edges.
  • the cutting tool of the present invention is free of this problem. With the arrangement of the present invention, it is possible to form a cutting tool which is small in diameter but sufficiently large in effective length of its cutting edges.
  • Figs. 1 and 2 show two basic forms of the rotary cutting tool according to the present invention.
  • Numeral 1 in these figures indicates an insert formed solely from an ultra-high-pressure sintered compact or without a base metal.
  • 2 indicates a tool body made of a cemented carbide.
  • the insert 1 made of an ultra-high-pressure sintered compact is brazed under vacuum to the tool body 2 through a bonding layer 3 of Ti-containing activated silver as a brazing metal.
  • the insert 1 of an ultra-high-pressure sintered compact is brazed to the tool body 2 by forming a coating 4 of TiC, TiN or TiCN formed on the insert 1 by PVD or CVD process and brazing in the atmosphere by use of an ordinary silver brazing metal with the coating as the bonding surface.
  • the bond layer 5 of a brazing metal anchors rigidly to both the coating 4 and the tool body 2.
  • the coating 4 should be formed only on the joint surface as shown.
  • the insert formed from an ultra-high-presure sintered compact should have a thickness of not more than 2 mm and not less than 1 mm.
  • Figs. 4A, 4B show a typical helical insert formed from an ultra-high-pressure sintered compact and used for a rotary cutting tool according to the present invention. We will later describe the method of manufacturing helical inserts 11.
  • Figs. 5A, 5B show a spiral end mill formed according to the method of the present invention, and having the helical inserts 11 shown in Figs. 4A, 4B.
  • Numeral 12 designates an end mill body (shank) having flutes 6 and cutting edges 7. If the end mill body 12 is formed from a cemented carbide, the flutes 6 are formed before sintering and the material is sintered to obtain a blank as the shark material. Then, helical inserts 11 of an ultra-high-pressure sintered compact are bonded to the respective flutes. If necessary, the inserts thus bonded are finish-machined to adjust their rake and clearance angles.
  • the helical inserts 11 may be bonded to the shank in either of the abovementioned two ways. They are bonded over the entire area of their surfaces 11b and 11c to the shank, so that the bond strength between the inserts and the shank is extremely high.
  • its axial rake ⁇ should be arranged so as to decrease to 0° or near 0° at its tip.
  • the edge angle at the tip is blunted by providing a negative relief face 8 at its tip.
  • the width W of the negative relief face should be between 0.01 mm and 0.2 or 0.3 mm.
  • a circular land 9 (its width is preferably 0.01-0.15 mm) may be provided along the cutting edge to strengthen the cutting edge and thus to improve the roughness of the finished surface.
  • An end mill having negative relief faces 0.03 mm in width W and circular land 9 having a width w 0.03 mm suffered no chippings either at the tips of the cutting edges nor along their outer periphery even after cutting a workpiece by 1000 m. Also, the cut surface formed by this end mill was the smoothest.
  • Figs. 6 and 7 merely show preferable arrangements for tools of this type. They are not essential features of the present invention.
  • the helical insert 11 has a top surface 11a that curves arcuately with a predetermined curvature as viewed from one end of the insert, and side faces 11b and 11c that extend helically with a predetermined helix angle Its bottom surface 11d also curves arcuately as viewed from one end of the insert. But it may be flattened afterward according to the shape of the seating face.
  • the insert 11 is made essentially from ultra-high-pressure sintered compact. That is, it has no base metal.
  • the helical insert 11 is formed as follows:
  • a block 20 of an ultra-high-pressure sintered compact is prepared.
  • Cylindrical members 21 are formed by cutting the block 20 with an electrical discharge cutting wire.
  • a material 21 is cut out from the block 20 so as to diametrically extend.
  • materials 21 are cut out so as to extend vertically.
  • a cylindrical member should be formed in the manner shown in Fig. 8. If a tool having a large diameter is needed or if it is desired to cut as many cylindrical members as possible having the same diameter or different diameters from a single block, the cylindrical member or members should be formed in the manner shown in Fig. 9.
  • after cutting a single diametrically extending cylindrical member it is possible to cut a plurality of additional members extending vertically or laterally and having different diameters or lengths from the remaining portion of the block on both sides of the first diametrically extending member.
  • each cylindrical member 21 shown When cutting vertically extending cylindrical members from the block, they may be cut concentrically as shown in Fig. 10. With this arrangement, material loss is zero. In the arrangement in Fig. 9, if it is desired to form as many cylindrical members as possible from a single block, one or more cylindrical members may be additionally formed concentrically inside each cylindrical member 21 shown.
  • An electrical discharge cutting wire CW arranged opposite to one end face of a cylindrical member 21 as shown in Fig. 11A is pressed against the end face along its diametrical line, and advanced, while rotating the member about its axis, at a predetermined constant speed to its other end face as shown in Fig. 11B.
  • the wire is fed through the member in the same manner as above to form a helical insert 11 of ultra-high-pressure sintered compact as shown in Figs. 4.
  • the hatched portion shown in Fig. 13 and defined between the cut faces C shown in Fig. 12 represents the insert 11.
  • the cutting wire should be moved through the member so that the cut faces C that define the side faces 11b, 11c of the insert (Fig. 4) will intersect the axis of the cylindrical member 21 as shown in Fig. 13.
  • the helical inserts 11 thus formed are bonded to the flutes formed in a blank of a tool body. Then, if necessary, their rake and clearance angles are adjusted by finish machining.
  • cutting tools can be manufactured at low cost.
  • the thickness of the insert remains substantially unchanged even after finishing it.
  • the diameters of the cylindrical member and the tool may be different, such a difference should be as small as possible to minimize the amount of material removed by grinding the insert.
  • Inserts may be formed from a columnar member. By cutting such a columnar member so that the cut faces intersect the axis of the columnar member as shown in Fig. 13, an insert having a wedge-shape cross-section is obtained.
  • Method A shown in the table is the method disclosed in Unexamined Japanese Patent Publication 3-10707, in which a layer of ultra-high-pressure sintered compact is formed around a base metal as a core to provide a cylindrical member, and the member is cut longitudinally along a helical cut line.
  • Various jigs are used to apply pressure and temperature uniformly to the sintered compact when sintering it under ultra-high pressure.
  • the gaps of such jigs and the sintered compact have to be kept as small as possible. Also, in such ultra-high-pressure condition, the sintered compact tends to be deformed.
  • a single sintered compact should be in principle formed by sintering the material only once. If two or more materials arranged in parallel to each other are sintered at a time, the yield tends to drop markedly. Thus, in Method A, only one sintered compact was formed at a time.
  • Method B is the method disclosed in Unexamined Patent Publication 3-277412, in which helical grooves are formed in a sintered compact member as a substrate, a material of an ultra-high-pressure sintered compact is charged in the grooves, and the material is sintered and at the same time bonded to the substrate.
  • Method B too, only one sintered compact is formed at a time.
  • only one end mill can be formed from one sintered compact.
  • cylindrical members 10.5 mm in diameter were obtained from a single block of ultra-high-pressure sintered compact. 16 helical chips were formed from each cylindrical member.
  • Methods A and B different materials are sintered simultaneously, so that they tend to develop cracks during sintering. This leads to an increase in the number of defectives produced in the subsequent manufacturing steps and thus lower yield.
  • Method B was lower in yield than Method A, because the sintered compact used in Method B is complicated in shape and thus more likely to be deformed and produce greater number of defectives.
  • the yield was 95%. Namely, an average of 15.2 end mills were obtained from one raw material. The manufacturing efficiency was about 5 times higher than in Method A and about 30 times higher than in Method B.
  • the unit price of end products considering the fact that the cost for final processing of a sintered compact accounts for about 50% of the total cost, such unit price will be approximately 2.5 times, in the case of Method A, and 1.5 times, in the case of Method B, the unit price of the end products produced according to the method of the present invention.
  • the ultra-high-pressure sintered compact used in the present invention may be one of the following:
  • Inevitable impurities herein referred to include e.g. alumina.
  • inserts made solely of hard sintered compact can be rigidly bonded to the tool body by brazing.
  • helical inserts of ultra-high-pressure sintered compact can be manufactured at high yield.
  • the method of the invention is free of the problems of low manufacturing efficiency of inserts, high production cost due to high tool machining cost, and low productivity. According to the method of the invention, it is possible to manufacture a high-performance, high-precision, long-life, low-cost rotary cutting tool having cutting edges of ultra-high-pressure sintered compact.
  • the helical insert of ultra-high-pressure sintered compact according to the present invention is formed by cutting cylindrical or columnar member longitudinally along helical lines.
  • its helix angle is not limited at all. In other words, its helix angle can be increased to any desired degree to improve its cutting ability.
  • a plurality of raw materials are cut from a single block.
  • a plurality of helical inserts are obtained from each raw material by cutting it into a plurality of pieces.
  • the manufacturing efficiency improves several times and the yield is correspondingly high.
  • method of present invention method A method B Number of cylindrical materials obtained by one sintering 4 1 1 Yield in sintering process 95% 70% 50% Number of helical inserts obtained from one material 16 16 4 Number of helical inserts obtained by one sintering 64 16 4 Number of end mills obtained per one sintering 15.2 2.8 0.5 Ratio of price of end mill 1 2.5 15
EP95110087A 1994-07-06 1995-06-28 Rotary cutting tool and method of manufacturing the same Expired - Lifetime EP0695596B1 (en)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP154469/94 1994-07-06
JP15446994 1994-07-06
JP16701794 1994-07-19
JP167017/94 1994-07-19
JP100903/95 1995-04-25
JP7100903A JPH0885012A (ja) 1994-07-06 1995-04-25 回転切削工具、同工具用超高圧焼結体ねじれチップ及びその工具、チップの製造方法

Publications (2)

Publication Number Publication Date
EP0695596A1 EP0695596A1 (en) 1996-02-07
EP0695596B1 true EP0695596B1 (en) 1999-05-12

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EP95110087A Expired - Lifetime EP0695596B1 (en) 1994-07-06 1995-06-28 Rotary cutting tool and method of manufacturing the same

Country Status (5)

Country Link
US (1) US5807032A (ja)
EP (1) EP0695596B1 (ja)
JP (1) JPH0885012A (ja)
KR (1) KR100210432B1 (ja)
DE (1) DE69509600T2 (ja)

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DE10238334A1 (de) * 2002-08-16 2004-02-26 Sandvik Ab Bohr- oder Fräswerkzeug und Verfahren zu dessen Herstellung
JP3352279B2 (ja) * 1995-04-06 2002-12-03 住友電気工業株式会社 スパイラルエンドミルおよびその製造方法
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KR100210432B1 (ko) 1999-07-15
JPH0885012A (ja) 1996-04-02
DE69509600T2 (de) 2000-01-20
DE69509600D1 (de) 1999-06-17
KR960003868A (ko) 1996-02-23
EP0695596A1 (en) 1996-02-07
US5807032A (en) 1998-09-15

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